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Suzuki SX4 Service Manual

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Table of Contents
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the words
WARNING
CAUTION
,
!
!
lighted by these signal words.
WARNING
!
Indicates a potential hazard that could result in death or injury.
CAUTION
!
Indicates a potential hazard that could result in vehicle damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
WARNING
!
This service manual is intended for authorized Suzuki dealers and qualified service technicians only.
Inexperienced technicians or technicians without the proper tools and equipment may not be able to
properly perform the services described in this manual.
Improper repair may result in injury to the technician and may render the vehicle unsafe for the driver
and passengers.
WARNING
!
For vehicles equipped with a Supplemental Restraint (Air Bag) System:
• Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to "Air Bag System Components and Wiring Location View" under
"General Description" in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and "Ser-
vice Precautions" under "On-Vehicle Service" in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
• If the air bag system and another vehicle system both need repair, Suzuki recommends that the air
bag system be repaired first, to help avoid unintended air bag system activation.
• Do not modify the steering wheel, instrument panel or any other air bag system component on or
around air bag system components or wiring. Modifications can adversely affect air bag system
performance and lead to injury.
• If the vehicle will be exposed to temperatures over 93 °C (200 °F), for example, during a paint baking
process, remove the air bag system components, that is air bag (inflator) modules, SDM and/or seat
belt with pretensioner, beforehand to avoid component damage or unintended activation.
The circle with a slash in this manual means "Don't do this" or "Don't let this happen".
IMPORTANT
and NOTE have special meanings. Pay special attention to the messages high-

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  Also See for Suzuki SX4

  Summary of Contents for Suzuki SX4

  • Page 1 Either of these two conditions may result in severe injury. • If the air bag system and another vehicle system both need repair, Suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.
  • Page 3 Strict observance of the so specified items will enable one to obtain the full performance of the vehicle. When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials as specified in each description.
  • Page 4 Some parts and accessories are sold as SUZUKI authorized replacement parts and accessories. Some genu- ine SUZUKI parts and accessories are sold as re-use parts and accessories. These parts and accessories are non-genuine Suzuki parts and accessories and use of these parts are not covered under warranty.
  • Page 5: Table Of Contents

    TABLE OF CONTENTS Volume 1 Volume 2 Precautions............... 00-i Precautions............... 00-i Precautions ............00-1 Precautions ............00-1 General Information ........... 0-i Steering ............... 6-i General Information ..........0A-1 Precautions .............. 6-1 Maintenance and Lubrication ......... 0B-1 Steering General Diagnosis ........6A-1 Steering Wheel and Column ........6B-1 Engine .................
  • Page 7 Table of Contents 00- i Section 00 Precautions CONTENTS Precautions ..........00-1 Air Bag Warning ..........00-10 Air Bag System Service Warning ...... 00-10 Precautions............00-1 Fastener Caution..........00-11 Precautions for Vehicles Equipped with a Suspension Caution .......... 00-11 Supplemental Restraint (Air Bag) System ..00-1 Wheels and Tires Caution.........
  • Page 8: Precautions

    • If the air bag system and another vehicle the tester may deploy the air bag or activate system both need repair, SUZUKI the pretensioner. recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.
  • Page 9 Precautions: 00-2 Servicing and Handling • After an air bag (inflator) module has been deployed, the surface of the air bag may WARNING contain a powdery residue. This powder consists primarily of cornstarch (used to Many of service procedures require lubricate the bag as it inflates) and by- disconnection of “A/B”...
  • Page 10 00-3 Precautions: • Even when the accident was light enough not to WARNING cause air bags to activate, be sure to inspect system parts and other related parts according to instructions • For handling and storage of a SDM, select under “Repair and Inspection Required after Accident a place where the ambient temperature in Section 8B”.
  • Page 11: General Precautions

    Precautions: 00-4 General Precautions • Be sure to observe following instructions S7RW0A0000002 when handling service materials such as The WARNING and CAUTION describe some general fuel, oil, fluid, coolant, grease, sealant, precautions that you should observe when servicing a thread lock cement, etc. Otherwise, your vehicle.
  • Page 12 When use of a certain type of lubricant, bond or reconnecting the battery, connect the positive cable sealant is specified, be sure to use the specified type. first and then the negative cable, and replace the terminal cover. “A”: Water tight sealant 99000–31250 (SUZUKI Bond No.1207F) I2RH01010027-01 I2RH01010030-01...
  • Page 13: Warning For Wheel (With Tire) Removal

    Precautions: 00-6 • Be sure to use special tools when instructed. Special tool (A): 09917–98221 (B): 09916–58210 I2RH01010034-01 • Use care not to expose connectors and electrical parts to water which will be a cause of a trouble. I2RH01010031-01 • When disconnecting vacuum hoses, attach a tag describing the correct installation positions so that the hoses can be reinstalled correctly.
  • Page 14: Precautions In Servicing 4Wd Model

    00-7 Precautions: Precautions in Servicing 4WD Model • When testing with 2-wheel brake tester, be S7RW0A0000004 sure to observe the following instructions. CAUTION Otherwise, drivetrain damage and personal injury may result. • Never perform any of the following [A], [B] –...
  • Page 15: Precautions For Installing Mobile Communication Equipment

    Precautions: 00-8 Precautions for Installing Mobile Precautions for Electrical Circuit Service S7RW0A0000008 Communication Equipment • When replacing a fuse, make sure to use a fuse of the S7RW0A0000006 When installing mobile communication equipment such specified capacity. Use of a fuse with a larger capacity as CB (Citizens-Band)-radio or cellular-telephone, be will cause a damage to the electrical parts and a fire.
  • Page 16 00-9 Precautions: • When connecting connectors, also hold connectors • Be careful not to touch the electrical terminals of parts and put them together until they lock securely (a click which use microcomputers (e.g. electronic control unit is heard). like as ECM, PCM, P/S controller, etc.). The static electricity from your body can damage these parts.
  • Page 17: Air Bag Warning

    Never connect probe where male terminal is only by an authorized SUZUKI dealer. Refer supposed to fit. to “Air Bag System Components, Wiring and Connectors Location in Section 8B” in...
  • Page 18: Fastener Caution

    00-11 Precautions: Fastener Caution ABS Caution S7RW0A0000011 S7RW0A0000015 CAUTION • When ABS control module is removed / installed, do not use impact wrenches which generate shock or When fasteners are removed, always reinstall impact to avoid damaging sensors in ABS control them at the same location from which they module.
  • Page 19: Repair Instructions

    Precautions: 00-12 Repair Instructions Electrical Circuit Inspection Procedure 4) Using continuity check or voltage check the following S7RW0A0006001 procedure, check the wire harness for open circuit While there are various electrical circuit inspection and poor connection with its terminals. Locate methods, described here is a general method to check abnormality, if any.
  • Page 20 00-13 Precautions: Voltage Check Short Circuit Check (Wire Harness to Ground) If voltage is supplied to the circuit being checked, voltage 1) Disconnect negative (–) cable at battery. check can be used as circuit check. 2) Disconnect connectors at both ends of the circuit to 1) With all connectors connected and voltage applied to be checked.
  • Page 21: Intermittent And Poor Connection Inspection

    Precautions: 00-14 Intermittent and Poor Connection Inspection • Poor terminal-to-wire connection. S7RW0A0006002 Check each wire harness in problem circuits for poor Most intermittent are caused by faulty electrical connection by shaking it by hand lightly. If any connections or wiring, although a sticking relay or abnormal condition is found, repair or replace.
  • Page 22 00-15 Precautions:...
  • Page 23: Maintenance And Lubrication

    Table of Contents 0- i Section 0 General Information CONTENTS General Information ........ 0A-1 Fuel Evaporative Emission Control System Inspection............0B-7 General Description ..........0A-1 Brake Discs and Pads (Front) Inspection....0B-7 Abbreviations ............0A-1 Brake Drums and Shoes (Rear) Inspection ..0B-7 Symbols .............. 0A-2 Brake Hoses and Pipes Inspection .....0B-8 Wire Color Symbols ..........
  • Page 24: Electronic Stability Program

    0A-1 General Information: General Information General Information General Description Abbreviations S7RW0A0101001 4WD: 4 Wheel Drive ABDC: After Bottom Dead Center GEN: Generator ABS: Anti-lock Brake System GND: Ground AC: Alternating Current GPS: Global Positioning System A/C: Air Conditioning A-ELR: Automatic-Emergency Locking Retractor HVAC: Heating, Ventilating and Air Conditioning A/F: Air Fuel Mixture Ratio HC: Hydrocarbons...
  • Page 25: Differential

    WU-TWC: Warm Up Three Way Catalytic Converter Symbols S7RW0A0101002 Symbol Definition Symbol Definition Tightening torque Apply SUZUKI BOND NO. 1216B 99000-31230 Apply oil (engine, transmission, transfer, Apply SILICONE SEALANT differential) 99000-31120 Apply fluid (brake, power steering or Apply SEALING COMPOUND 366E...
  • Page 26 0A-3 General Information: There are two kinds of colored wire used in this vehicle. One is single-colored wire and the other is dual-colored (striped) wire. The single-colored wire uses only one color symbol (i.e. “GRN”). The dual-colored wire uses two color symbols (i.e. “GRN/YEL”). The first symbol represents the base color of the wire (“GRN”...
  • Page 27 General Information: 0A-4 Standard Tightening Torque Each fastener should be tightened to the torque specified in each section. If no description or specification is provided, refer to the following tightening torque chart for the applicable torque for each fastener. When a fastener of greater strength than the original one is used, however, use the torque specified for the original fastener.
  • Page 28: Rear Suspension

    0A-5 General Information: Vehicle Lifting Points S7RW0A0101005 WARNING • Before applying hoist to underbody, always take vehicle balance throughout service into consideration. Vehicle balance on hoist may change depending on what part to be removed. • Before lifting up the vehicle, check to be sure that end of hoist arm is not in contact with brake pipe, fuel pipe, bracket or any other part.
  • Page 29: Vehicle Identification Number

    General Information: 0A-6 Vehicle Identification Number In raising front or rear vehicle end off the floor by jacking, be sure to put the jack against engine front mounting S7RW0A0101006 The number is punched on the front dash panel in member (1) or rear jacking bracket (2). engine room and it is also attached on the left side of instrument panel depending on the vehicle specification.
  • Page 30 0A-7 General Information: Component Location Warning, Caution and Information Labels Location S7RW0A0103001 The figure shows main labels among others that are attached to vehicle component parts. When servicing and handling parts, refer to WARNING / CAUTION instructions printed on labels. If any WARNING / CAUTION label is found stained or damaged, clean or replace it as necessary.
  • Page 31: General Information

    General Information: 0A-8 I7RW0A010001-01 1. Air bag label on driver air bag (inflator) module 7. Pretensioner label on seat belt retractor 2. Air bag label on contact coil assembly 8. Side/Curtain air bag label on pillar (both right and left sides) (if equipped) 3.
  • Page 32: Maintenance Schedule Under Normal Driving

    0B-1 Maintenance and Lubrication: Maintenance and Lubrication General Information Precautions Precautions for Maintenance and Lubrication S7RW0A0200001 Air Bag Warning Refer to “Air Bag Warning in Section 00”. Scheduled Maintenance Maintenance Schedule under Normal Driving Conditions S7RW0A0205001 NOTE • This interval should be judged by odometer reading or months, whichever comes first. •...
  • Page 33 Maintenance and Lubrication: 0B-2 Km (x 1,000) Interval Miles (x 1,000) Months Inspect at first 15,000 km (9,000 miles Brake lever and cable (damage, stroke, operation) (I: only Chassis and body Clutch pedal (travel) Clutch fluid (leakage, level) (I: — —...
  • Page 34 0B-3 Maintenance and Lubrication: Severe Maintenance Maintenance Maintenance interval condition code operation Every 15,000 km (9,000 miles) or 12 months – B C D – – – – Accessory drive belt Every 45,000 km (27,000 miles) or 36 months Every 7,500 km A –...
  • Page 35 Maintenance and Lubrication: 0B-4 Accessory Drive Belt Replacement Before draining engine oil, check engine for oil leakage. S7RW0A0206002 If any evidence of leakage is found, make sure to correct Water Pump and Generator Drive Belt defective part before proceeding to the following work. Replace belt with new one referring to “Water Pump / 1) Drain engine oil by removing drain plug.
  • Page 36 0B-5 Maintenance and Lubrication: 4) Screw new filter on oil filter stand by hand until the Engine oil specification filter O-ring contacts mounting surface. Oil pan capacity: About 3.7 liters (7.8 / 6.5 US / lmp pt.) CAUTION Oil filter capacity: About 0.2 liter (0.4 / 0.3 US / To tighten oil filter properly, it is important to lmp pt.) accurately identify the position at which filter...
  • Page 37 Maintenance and Lubrication: 0B-6 Exhaust System Inspection S7RW0A0206006 WARNING To avoid danger of being burned, do not touch exhaust system when it is still hot. Any service on exhaust system should be performed when it is cool. When carrying out periodic maintenance, or the vehicle is raised for other service, check exhaust system as follows: I2RH01140007-01...
  • Page 38: Inspection

    0B-7 Maintenance and Lubrication: Fuel Tank Inspection Brake Discs and Pads (Front) Inspection S7RW0A0206012 S7RW0A0206015 Check fuel tank damage, cracks, fuel leakage, corrosion 1) Remove wheel and caliper but don’t disconnect and tank bolts looseness. brake hose from caliper. If a problem is found, repair or replace. 2) Check front disc brake pads and discs for excessive wear, damage and deflection.
  • Page 39: Brake Hoses And Pipes Inspection

    Maintenance and Lubrication: 0B-8 Brake Hoses and Pipes Inspection 2) Check tooth tip of each notch for damage or wear. If S7RW0A0206017 any damage or wear is found, replace parking lever. Perform this inspection where these is enough light and 3) Check parking brake lever for proper operation and use a mirror as necessary.
  • Page 40: Tires Inspection

    0B-9 Maintenance and Lubrication: Tires Inspection Suspension System Inspection S7RW0A0206021 S7RW0A0206024 1) Check tires for uneven or excessive wear, or • Inspect front struts and rear shock absorbers for evidence of oil leakage, dents or any other damage on damage. If defective, replace. Refer to “Irregular and/or Premature Wear sleeves;...
  • Page 41: Drive Shaft (Axle) Boots Inspection

    Maintenance and Lubrication: 0B-10 Propeller Shaft (4WD) Inspection 2) Check bolts and nuts for tightness and retighten them as necessary. Repair or replace defective S7RW0A0206027 1) Check propeller shaft connecting bolts for parts, if any. looseness. If looseness is found, tighten to specified 3) Check steering linkage for looseness and damage.
  • Page 42: Transfer Oil Inspection (4Wd)

    0B-11 Maintenance and Lubrication: Transfer Oil Inspection (4WD) HVAC Air Filter (If Equipped) Replacement S7RW0A0206033 S7RW0A0206039 Check transfer oil for leakage, contamination and level Replace HVAC air filter with new one referring to “HVAC referring to “Transfer Oil Level Check in Section 3C”. Air Filter Removal and Installation (If Equipped) in Section 7A”.
  • Page 43: Specifications

    Maintenance and Lubrication: 0B-12 Clutch (for Manual Transaxle) Steering Check for the following. • Check to ensure that steering wheel is free from • Clutch is completely released when depressing clutch instability, or abnormally heavy feeling. pedal, • Check that the vehicle does not wander or pull to one •...
  • Page 44: Special Tools And Equipment

    0B-13 Maintenance and Lubrication: Special Tools and Equipment Recommended Fluids and Lubricants S7RW0A0208001 Engine oil SG, SH, SJ, SL or SM grade (Refer to “Engine Oil and Filter Change” for engine oil viscosity.) Engine coolant “Antifreeze/Anticorrosion coolant” (Ethylene glycol base coolant) Brake fluid Refer to reservoir cap of brake master cylinder.
  • Page 45 Table of Contents 1- i Section 1 Engine CONTENTS Precautions ..........1-1 DTC Clearance ..........1A-26 Troubleshooting for Communication Error Precautions............. 1-1 with Scan Tool Using CAN......1A-26 Precautions for Engine.......... 1-1 DTC Table............1A-32 Engine General Information and Fail-Safe Table..........1A-36 Scan Tool Data ..........1A-38 Diagnosis ..........
  • Page 46 1-ii Table of Contents DTC P0118: Engine Coolant Temperature DTC P0617: Starter Relay Circuit High ...1A-141 Circuit High .............1A-84 DTC P1510: ECM Back-Up Power Supply DTC P0122: Throttle Position Sensor (Main) Malfunction............1A-143 Circuit Low ............1A-87 DTC P2101: Throttle Actuator Control Motor DTC P0123: Throttle Position Sensor (Main) Circuit Range / Performance......1A-144 DTC P2102: Throttle Actuator Control Motor...
  • Page 47 Table of Contents 1-iii Vacuum Hose Inspection ........1B-3 Camshaft Position Control (VVT Variable EVAP Canister Purge Valve Inspection ....1B-3 Valve Timing) System Description ....1D-3 EVAP Canister Inspection........1B-4 Diagnostic Information and Procedures ....1D-5 EGR Valve Removal and Installation (If Compression Check..........1D-5 Equipped)............
  • Page 48 1-iv Table of Contents Main Bearings, Crankshaft and Cylinder Radiator Cooling Fan Disassembly and Block Removal and Installation .......1D-59 Reassembly ............1F-9 Crankshaft Inspection ........1D-62 Radiator On-Vehicle Inspection and Cleaning ..1F-9 Main Bearings Inspection........1D-64 Radiator Removal and Installation ...... 1F-9 Sensor Plate Inspection ........1D-68 Water Pump / Generator Drive Belt Tension Rear Oil Seal Inspection ........1D-68...
  • Page 49 Table of Contents 1-v Ignition System Wiring Circuit Diagram....1H-2 Charging System ........1J-1 Component Location ...........1H-3 General Description ..........1J-1 Ignition System Components Location ....1H-3 Battery Description..........1J-1 Diagnostic Information and Procedures....1H-4 Generator Description ......... 1J-2 Ignition System Symptom Diagnosis....1H-4 Diagnostic Information and Procedures .... 1J-3 Reference Waveform of Ignition System.....1H-4 Battery Inspection ..........
  • Page 50: Precautions

    1-1 Precautions: Precautions Engine Precautions Precautions for Engine S7RW0A1000001 Air Bag Warning Refer to “Air Bag Warning in Section 00”. Precautions on Engine Service Refer to “Precautions on Engine Service in Section 1